Abstract
Keywords
CFD, air flow, brake boosters, master cylinders, VSC
Abstract
The objective of this paper is to present different real applications of CFD simulation to the design, development and optimization of braking components.
First, CFD has been applied to optimize the performance of the regulating valve of a brake booster. With the help of CFD simulations, the valve design has been anlayzed and modified in order to increase the air flow and improve the efficiency and response of the booster. The experimental efficiency tests performed on the physical prototype that was designed with the help of CFD techniques showed a significant improvement in efficiency and a much faster response.
Second, CFD has been applied to assess the performance of an engine breather design that takes air from the engine compartment and conducts it to the brake booster inlet. The aim of the calculation was to ensure that the breather does not introduce significant pressure drops that reduce the air flow and worsen the efficiency and response of the brake. The efficiency tests performed on the physical breather showed that the CFD predictions were correct.
Finally, CFD simulation can also be applied to the design of master cylinders, in particular, to calculate the dimensions of the flow channels necessary to ensure the minimum mass flow from the brake liquid reservoir that is needed for the correct performance of the VSC (Vehicle Stability Control) pump. The CFD calculations were validated with the flow measurements in an initial design and then used to analyze the dependence flow-pressure and identify the critical regions and modify their dimensions in order to achieve the desired flow rate.